Processes for preparing crystalline and amorphous mupirocin calcium

ABSTRACT

Processes are provided for preparing mupirocin calcium dihydrate from pseudomonic acid in a two phase system by using an organic carboxylate. 
     A highly pure composition of amorphous mupirocin calcium is provided, and processes for its preparation by solvent removal, lyophilization and precipitation with use of an anti-solvent. Pharmaceutical compositions of amorphous form, and methods of using them to treat infections are also provided. 
     Also provided are combined processes for preparing mupirocin calcium dihydrate and amorphous, by producing amorphous form first, followed by conversion of amorphous form into the dihydrate through crystallization from an aqueous solution. Also provided are processes for removing the water of crystallization of the dihydrate to obtain mupirocin calcium anhydrate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the following U.S. ProvisionalApplications No. 60/344,117, filed Dec. 28, 2001; No. 60/344,118, filedDec. 28, 2001; No. 60/348,142, filed Jan. 11, 2002; No. 60/348,183,filed Jan. 11, 2002; No. 60/360,721, filed Mar. 1, 2002; and No.60/368,735, filed Mar. 29, 2002.

FIELD OF THE INVENTION

The present invention relates to the solid state chemistry of theantibiotic pseudomonic acid A. Particularly, the present inventionrelates to processes for preparing crystalline and amorphous forms ofmupirocin calcium.

BACKGROUND OF THE INVENTION

Pseudomonic acid A is an antibiotic that has a growth inhibiting effectmainly against Gram positive bacteria (e.g. Staphylococcus aureus,Streptococcus pyogenes, Streptococcus pneumoniae, Klebsiella pneumoniae)and some Gram negative bacteria (e.g. Haemophilus influenzae, Neisseriagonorrhoeae) [A. Ward, D. M. Campoli-Richards, Drugs 32, 425-444 (1986)]and its minimal inhibiting concentration is in the range of 0.02-0.5mg/dm³. Pseudomonic acid A, by inhibiting the isoleucine-tRNA synthaseenzyme, affects the peptide synthesis of pathogen bacteria [J. Hughesand G. Mellows, Biochem. J. 191, 209-219 (1980)]. An advantageousfeature of this antibiotic is that it has very low toxicity both forhumans and animals and it is negative in the Ames test. Pseudomonic acidA is presently used in human therapy, in various formulations, for thetreatment of skin infections (e.g. impetigo, pyoderma), nose andexternal ear infections, acne, burns, eczema, psoriasis, in case ofulceration for treatment of secondary infections, and for prevention ofhospital infections.

The chemical structure of pseudomonic acid A is9-{4[5S(2S,3S-epoxy-5S-hydroxy-4S-methylhexyl)-3R,4R-dihydroxy-tetrahydropyran-2S-yl]-3-methylbut-2(E)-enoyloxy}nonanoicacid [E. B. Chain and G. Mellows, J. C. S. Chem. Comm. 847-848 (1974);R. G. Alexander, J. P. Clayton, K. Luk, N. H. Rogers, T. J. King, J. C.S. Perkin I. 561-565 (1978)], as depicted by formula (I):

It is known that Pseudomonas fluorescens is able to produce thepseudomonic acid A. According to the British Patent No. 1,395,907, thePseudomonas fluorescens NCIB 10586 strain is able to biosynthesize thepseudomonic acid complex consisting of pseudomonic acid A and its isomerbeing a double bond in the cis position between the carbon atoms C₂ andC₃ and pseudomonic acid B. The ratio of the components is 4.5:4.5:1.According to the Japanese patent application No. 52-70083, however, thePseudomonas fluorescens Y-11633 strain is able to biosynthesize thepseudomonic acid complex consisting of the pseudomonic acid A,pseudomonic acid B and further two components with unknown structures inthe ratio of 9:0.5:0.5.

Mupirocin calcium, an antibiotic derived from pseudomonic acid iscurrently marketed in the United States as Bactroban®. Bactroban® isrecommended for treatment of secondarily infected traumatic skin lesionscaused by strains of Staphylococcus aureus and Streptococcus pyogenes.Bactroban® is sold as a topical cream or a nasal ointment and has acalcium salt strength of 2% equivalent base. According to the maker ofBactroban®, mupirocin calcium could be administered orally at 500 mg,and intravenously at 250 mg without any major side effects.

Mupirocin calcium is especially effective against gram-positivebacteria, but may also be used against gram negative bacteria. Itinhibits bacterial protein synthesis by irreversibly binding tobacterial isoleucyl transfer-RNA synthetase.

The calcium salt of pseudomonic acid (“mupirocin calcium”) has beendisclosed in various patents. U.K. Pat. Nos. 1,577,545 and 1,577,730,incorporated herein by reference, disclose the use of mupirocin calciumin the treatment of diseases. The '545 patent is directed to thetreatment and prevention of swine dysentery with the calcium salt ofmupirocin. The '730 patent is directed to the use of the calcium salt ofmupirocin to treat respiratory, venereal and mycoplasma-induced diseasesin non-human mammals. The disclosure focuses on the efficacy ofmupirocin as a drug, rather than its preparation.

U.S. Pat. No. 4,879,287 is directed to a pharmaceutical composition ofmupirocin calcium for topical administration comprising hydratedcrystalline calcium salt, and a corticosteroid. The '287 patentdiscloses various formulations for crystalline mupirocin calcium and isincorporated herein by reference.

U.S. Pat. Nos. 5,596,672, 5,436,266, 5,191,093 and 4,916,155 (Baker etal.), all within the same family, disclose a crystalline calcium salt ofmupirocin, and claim its composition, method of preparation andadministration. All these patents are incorporated herein by reference.The '672 patent is directed to a method of treating bacterial infectionswith crystalline mupirocin calcium or a hydrate thereof. The '266 patentis directed to a hydrate of crystalline mupirocin calcium. The '155patent is directed to anhydrous crystalline mupirocin calcium. The '093patent is directed to a process for preparing crystalline mupirocincalcium or a hydrate thereof by “reacting pseudomonate ions with calciumions in solution in an aqueous solvent, recovering a crystalline calciumpseudomonate hydrate from the solution and thereafter optionallyremoving water of crystallization.”

The Baker et al. patents disclose preparing amorphous form of mupirocincalcium by crystallization from an aqueous solution consisting of 50%methanol followed by trituration with dry ether. Amorphous mupirocincalcium obtained in the patents exhibits a relatively low melting pointof 70-76° C., a relatively low assay of 89.9% (expressed as a percentageof pure free pseudomonic acid) and rapid deterioration at hightemperatures (chart in Columns 8 and 9 of the '093 and related patents).The Baker et al. patents disclose that “the readily isolable amorphousform of this salt has been found to be sparingly water soluble material,having a low melting point and poor thermal stability.” (Column 1, Lines31-33).

U.S. Pat. No. 4,639,534, incorporated herein by reference, discloses useof a lithium salt as an intermediate in isolating pseudomonic acid froma broth. The '534 patent extracts the broth to obtain mupirocin lithiumand hydrolyzes the salt to obtain pseudomonic acid.

A need exists in the art to prepare mupirocin calcium dihydrate with newprocesses. Processes which eliminate the use of a co-solvent areparticularly preferred in that removal of a co-solvent is a tedious stepand may lead to deterioration of the product. A need also exists in theart for a process for preparing a more pure and stable form of amorphousmupirocin calcium.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides a process for preparingcrystalline mupirocin calcium hydrate or an anhydrate thereof comprisingthe steps of preparing a solution of pseudomonic acid in awater-immiscible solvent, combining the solution with a solution or asuspension of a calcium C₂ to C₁₂ organic carboxylate in an aqueoussolvent, to form an aqueous and a non-aqueous phase, wherein mupirocincalcium dihydrate precipitates from the aqueous phase, separating theprecipitate and optionally converting the dihydrate to the anhydrate.Preferably, the aqueous suspension or solution is water free of aco-solvent or a mixture of water and a C₁ to a C₄ alcohol. Preferredorganic carboxylates are acetate, propanoate and hexanoate, with alkylsubstituted hexanoates such as 2-ethyl-hexanoate being more preferred.

In another aspect, the present invention provides a process forpreparing crystalline mupirocin calcium hydrate or an anhydrate thereofcomprising the steps of adding pseudomonic acid and a calcium C₂ to C₁₂organic carboxylate to an aqueous solvent to form a solution, wherein aC₂ to C₁₂ organic carboxylic acid forms, removing the carboxylic acid,separating mupirocin calcium dihydrate as a precipitate from the aqueoussolvent and optionally converting the dihydrate to the anhydrate.Preferably, the solvent is a mixture of water and a C₁ to a C₄ alcoholwhose water content is increased before the crystallization step.Preferably, the carboxylic acid is removed by extraction.

In another aspect, the present invention provides a process forpreparing crystalline mupirocin calcium dihydrate or an anhydratethereof comprising the steps of adding pseudomonic acid and calciumoxide to water free of a co-solvent to form a solution, whereinmupirocin calcium dihydrate precipitates from the solution, separatingthe mupirocin calcium dihydrate and optionally converting the dihydrateto the anhydrate.

In another aspect, the present invention provides a process forpreparing amorphous mupirocin calcium comprising the steps of addingpseudomonic acid, a base and a source of calcium ions to a C₁ to a C₄alcohol to form a solution and removing the alcohol. Preferably, thealcohol is substantially anhydrous, more preferably has less than about1% (vol/vol) water content and is selected from the group consisting ofmethanol and ethanol. Preferably, the alcohol is removed by evaporation.

In another aspect, the present invention provides a process forpreparing amorphous mupirocin calcium comprising the steps of addingpseudomonic acid, a base and a source of calcium ions to a C₁ to a C₄alcohol to form a solution, combining the solution with an anti-solventto precipitate amorphous mupirocin calcium and separating theprecipitate. Preferably, the alcohol has less than about 1% (vol/vol)water content and is ethanol or methanol. The anti-solvent is preferablyan ester and an ether, such as methyl-t-butyl ether, diisopropyletherand i-butyl-acetate. Preferably, the solution is added to theanti-solvent.

In another aspect, the present invention provides a process forpreparing amorphous mupirocin calcium comprising the steps of addingpseudomonic acid, a base and a source of calcium ions to a solventselected from the group consisting of water, a C₁ to a C₄ alcohol andmixtures thereof to form a solution and lyophilizing the solution.Preferably the alcohol is methanol.

In another aspect, the present invention provides a process forpreparing crystalline mupirocin calcium dihydrate or an anhydratethereof comprising the steps of dissolving pseudomonic acid in awater-immiscible solvent to form a solution, combining the solution witha solution or suspension of a base and a source of calcium ions in anaqueous solvent, to form an aqueous and a non-aqueous phase, whereinmupirocin calcium dihydrate precipitates from the aqueous phase,separating the dihydrate and optionally converting the dihydrate to theanhydrate. Preferably the water-immiscible solvent is selected from thegroup consisting of esters and ketones, such as isobutyl acetate andisobutyl methyl ketone.

In another aspect, the present invention provides a process forpreparing amorphous mupirocin calcium comprising the steps of reactingpseudomonate ions and calcium ions in solution in a C₁ to a C₄ alcoholand evaporating the alcohol.

In another aspect, the present invention provides a process forpreparing amorphous mupirocin calcium comprising the steps of reactingpseudomonate ions and calcium ions in solution in a C₁ to a C₄ alcohol,adding the solution to an ester or an ether as an anti-solvent toprecipitate amorphous mupirocin calcium and separating the precipitate.

In another aspect, the present invention provides a process forpreparing amorphous mupirocin calcium comprising the steps of reactingpseudomonate ions and calcium ions in solution in water or a mixture ofwater and a C₁ to a C₄ alcohol and lyophilizing the solution.

In another aspect, the present invention provides a process forpreparing crystalline mupirocin calcium dihydrate or an anhydratethereof comprising the steps of providing pseudomonic acid and a calciumC₂ to C₈ organic carboxylate, exchanging acidic proton of thepseudomonic acid with the calcium ion of the C₂ to C₈ organiccarboxylate, recovering the mupirocin calcium dihydrate and optionallyconverting the dihydrate to the anhydrate.

The processes for preparing amorphous and dihydrate mupirocin calciumcan be combined, by first preparing amorphous form and then obtainingthe dihydrate from amorphous form. The dihydrate can optionally bedesolvated, if desired, to obtain the anhydrate form.

The present invention provides pharmaceutical compositions of amorphousmupirocin calcium and methods of their use in preventing or treatinginfections.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a Powder X-ray Diffraction (“PXRD”) pattern of the product ofExample 6.

FIG. 2 is a PXRD pattern of the product of Example 9.

FIG. 3 is a PXRD pattern of the product of Example 10.

FIG. 4 is a PXRD pattern of the product of Example 15.

FIG. 5 is a PXRD pattern of the product of Example 16.

FIG. 6 is a PXRD pattern of amorphous mupirocin calcium.

FIG. 7 is a Differential Scanning Calorimetry (“DSC”) thermogram ofamorphous mupirocin calcium.

FIG. 8 is a Fourier Transform Infrared (“FTIR”) spectrum of amorphousmupirocin calcium.

FIG. 9 is the thermal stability data of amorphous mupirocin calciumprepared by the process of the prior art.

FIG. 10 is the thermal stability data of amorphous mupirocin calciumprepared by the process of the prior art.

FIG. 11 is an illustration of the various impurities of mupirocin andhow they are referred to in the present invention and in the EuropeanPharmacopoeia (“EP”).

DETAILED DESCRIPTION OF THE INVENTION

The term “pseudomonate” refers to the ion obtained by removing ahydrogen from the carboxylic acid group of pseudomonic acid.Pseudomonate calcium is synonymous with mupirocin calcium.

As used herein, the term “co-solvent” refers to a second solvent used incombination with a first solvent in such amounts to provide desirablesolubility properties. Impurities and traces of a solvent are notco-solvents. Hence, water free of co-solvent can include small amountsof other solvents.

As used herein, the term “assay” refers to a determination ofpurity/presence of a quantity of a substance as described by theEuropean Pharmacopoeia (“EP”). EUROPEAN PHARMACOPOEIA, Fourth Edition,pp 1602-1604, Council of Europe, Strasbourg, 2001. The assay is donewith high pressure liquid chromatography (“HPLC”).

Baker et al. expresses its assay in relation to psuedomonic acid. Theassay of the present invention is expressed differently, as illustratedby Table-1.

TABLE 1 Conversion of the assay disclosed in Baker et al. Crystallinemupirocin calcium Anhydrous amorphous Pseudomonic Sample dihydratemupirocin calcium acid Melting Point 125-137 70-76 73-75 (° C.) Purity(%) 92.1* 98.88** 89.9* 93.29*** 91.9* Purity after storage 10 days, 50°C. 91.08 97.79 74.88 77.70 71.59 8 days, 80° C. 89.33 95.91 26.07 27.050 2 weeks, 37° C. 92.28 99.08 87.83 91.14 90.61 2 weeks, 50° C. 90.9097.60 72.0 74.71 51.18 2 weeks, 80° C. 86.57 92.95 12.58 13.05 0*expressed as a percentage of pure free pseudomonic acid. **expressed asa percentage of mupirocin calcium dihydrate. ***expressed as apercentage of mupirocin calcium anhydrous.

In connection with amorphous mupirocin calcium, the assay of the presentinvention can be converted into the assay expressed as in Baker et al.by multiplying with a factor of 0.9637. This 89.9% assay of Baker et al.corresponds to a 93.29% assay as calculated by the method of the presentinvention.

In connection with mupirocin calcium dihydrate, the 92.1% assay of Bakeret al. corresponds to a 98.88% assay as expressed by the presentinvention.

As used herein, the term “total impurity” refers to the sum of all areasunder the peaks of impurities as described by the EuropeanPharmacopoeia. It is determined by another HPLC method and is differentthan the assay.

The following hypothetic further explains the relationship between theassay and the impurities. For example, lets assume one is provided anactive pharmaceutical ingredient with 99% chemical purity (+1%impurity). After final drying, 3% water content (KF) is measured. Assayanalysis should give 96%. This is “assay as is”. Then one calculateswith the water inside to get assay to dry (or simply “assay”), whichshould give 99%.

The present invention provides for a highly purified amorphous form ofmupirocin calcium. The amorphous character and purity of the material wehave produced is confirmed by a powder X-ray diffraction patternobtained from a sample thereof, which is provided as FIG. 6. The patternis without intense focused reflections.

Amorphous mupirocin calcium prepared by the present invention is alsocharacterized by a DSC thermogram depicted in FIG. 7. The DSC thermogramdoes not show any discernible endotherms or exotherms. The FTIR spectrum(FIG. 8) exhibits the same peaks as those of amorphous mupirocin in theprior art.

The present invention provides amorphous mupirocin calcium with amelting point of about 76° C. to about 89° C., more preferably of about85° C. to about 89° C. The high melting point of amorphous mupirocincalcium confirms the high purity of the product.

The present invention provides for amorphous mupirocin calcium with highthermal stability. Thermal stability is defined as the ability to resistchemical degradation during storage, especially in light of theconditions during storage. The higher purity and melting points ofamorphous mupirocin calcium makes it less susceptible to chemicaldegradation during storage.

As demonstrated in Table 2, after 2 months of storage at about 25° C.and at about 2-8° C., the amorphous mupirocin calcium has an assay ofabout 96% as determined by the method of the present invention.Additionally, the total impurity content is almost unchanged at about 3%after 2 months.

TABLE 2a Thermal stability of 1 Kg batch of amorphous mupirocin calciumprepared by the process of Example 17. Period (months at 25° C.) AssayWater Total Impurity 0 98.5 1.5 Error 0.5 97.4 1.2 2.83 1 98.3 1.9 3.182 96.5 1.5 3.21

TABLE 2b Thermal stability of 1 Kg batch of amorphous mupirocin calciumprepared by the process of Example 17. Period (months at 2-8° C.) AssayWater Total Impurity 0 98.5 1.2 Error 0.5 95.2 1.3 2.71 1.0 95.5 1.92.88 2.0 96.7 1.6 2.86

TABLE 2c Thermal stability of 187.2 grams batch of amorphous mupirocincalcium prepared by the process of Example 17. Impurities (HPLC) PeriodAssay (%) Storage (Month) Description (HPLC) Water Total Cond. (%) Imp.C MUP II Impurities Specifications White or 93.0 to 100.5 NMT 1.5 NMT2.5 NMT 1.0 NMT 4.5 almost white powder 2° C.-8° C./ 0 White 96.0 0.61.31 0.31 2.22 60% RH powder 1 White 95.6 0.8 NA NA NA powder 2 White95.3 0.7 1.32 0.41 2.43 powder 3 White 96.1 1.1 1.35 0.42 2.62 powder

TABLE 2d Thermal stability of 187.2 grains batch of amorphous mupirocincalcium prepared by the process of Example 17. Impurities (HPLC) Assay(%) Storage Period (HPLC) Water Total Cond. (Month) Description (%) (%)Imp. C MUP II Impurities Specifications White or 93.0 to 100.5 NMT 1.5NMT 2.5 NMT 1.0 NMT 4.5 almost white powder 25° C./ 0 White 96.0 0.61.31 0.31 2.22 60% RH powder 1 White 97.5 0.8 NA NA NA powder 2 White94.1 0.8 1.34 0.77 3.02 powder 3 White 95.9 1.0 1.37 0.89 3.25 powder

The thermal stability of amorphous mupirocin calcium prepared by theprocess of Baker et al. shows a more rapid deterioration. FIGS. 9 and 10demonstrate that the total level of impurities of amorphous mupirocincalcium is more than about 3.5% (not assay) after two months of storagewith the method of Baker et al., whereas mupirocin calcium amorphousprepared according to the method of the present invention has a totallevel of impurity level of less than about 3.5% (not assay) and morepreferably less than about 3.3% after at least two months of storage at25° C. The amorphous mupirocin calcium of the present invention isparticularly stable in regard to an impurity labeled MUP II (Referred toas impurity E in the European Phamacopoia (EP), where storage at 25° C.and RH 60% for at least two months results in a level of the impurity ofNMT about 1%, more preferably less than about 0.8%, whereas amorphousmupirocin calcium produced by the art reaches a level of more than 1%after storage for one month.

As illustrated in FIG. 11, the impurities of the present inventioncorrespond to the EP in the following matter: IMP A of EP is B of thepresent invention; B of EP is C; C of EP is D; D of EP is I (one); E ofEP is II (two); and F of EP is E of the present invention.

The present invention provides a process for preparing amorphousmupirocin calcium comprising the steps of adding pseudomonic acid, abase, and a source of calcium ions to a C₁ to a C₄ alcohol to form asolution, and removing the alcohol. To prepare the solution, pseudomonicacid is dissolved in a C₁ to a C₄ alcohol, with methanol and ethanolbeing preferred. Preferably, the alcohol used is substantiallyanhydrous. The alcohols used preferably contain less than about 2%water, more preferably less than about 1% water (vol/vol).

After preparing a solution of pseudomonic acid in the alcohol, a base isadded to the solution, resulting in pseudomonate ions. Bases such assodium or potassium hydroxide can be used to neutralize the acid. Sinceneutralization of an acid with a base is well known in the art, one ofskill in the art would appreciate that other alternatives can be used.

The amount and concentration of the base used need not be exact. It isthe amount which is sufficient to neutralize a substantial part of thepseudomonic acid. One of skill in the art can appreciate that differentamounts of base used can be determined in a routine fashion, andvariations in the amount of base used may not change the results.

To obtain amorphous mupirocin calcium, a source of calcium ions is addedto the solvent. The present invention only requires the addition ofcalcium ions, and it is not as relevant what ion the calcium can becomplexed with as long as the other ion does not interfere with theresult. In one embodiment, the present invention uses a calcium salt ofa halogen, such as calcium chloride. The base and source of calcium ionscan be a single chemical species, e.g., calcium oxide or two differentchemical species. The term “a base and source of calcium ions”encompasses use of a single chemical species.

After the addition of all the necessary ingredients, the solution can bestirred. The solution can be stirred from about 30 minutes to about twohours. Stirring often influences the quality and quantity of thecrystals, which one of skill in the art can appreciate.

Depending on the base and calcium ions used, a separation step can beused to remove impurities such as salts formed as a result of thepresence of excess ions in the solution. In one embodiment potassiumhydroxide and calcium chloride are used as a base and a source ofcalcium ions. After addition of potassium hydroxide and calciumchloride, the unused potassium and chloride ions form a salt that can beseparated. Preferably, a filter is used to separate the formed potassiumchloride.

The solvent is then removed from the solution. Most preferably thesolvent is removed by evaporation. Various techniques well known in theart can be used to evaporate the solvent. For example, the solvent canbe evaporated under ambient or reduced pressure, depending upon thevolatility of the solvent. In a another embodiment, the solution can beheated to accelerate the evaporation. With high volatile solvents suchas methanol, the additional heating step may not be necessary. Thesolvent can also be evaporated with a rotary evaporator at ambient orreduced pressure.

After removal of the solvent, the residue can be optionally dried toreduce the amount of residual solvent. Drying can be done according toprocedures well known in the art. The residue can be dried at ambient orreduced pressure. It can optionally be heated to accelerate the dryingprocess, though it should not be heated beyond the melting point ofamorphous mupirocin calcium. Preferably, the product is heated fromabout 30° C. to about 50° C., most preferably no more than about 45° C.A vacuum oven known in the art can be used.

In another embodiment, amorphous mupirocin calcium is prepared by aprocess comprising the steps of adding pseudomonic acid, a base and asource of calcium ions to a C₁ to a C₄ alcohol to form a solution,combining an anti-solvent with the solution to precipitate amorphousmupirocin calcium and separating the precipitate. As used herein, theterm “anti-solvent” has its ordinary meaning in the art and refers to aliquid that is added to a solvent to reduce the solubility of acompound, such as a salt, in that solvent, resulting in precipitation ofthe salt. Mupirocin calcium has low solubility for the anti-solvent,causing the salt to precipitate. The solution can be prepared bycombining methanolic solutions of pseudomonic acid, a base such aspotassium hydroxide and a source of calcium ions, such as calciumchloride. The resulting solution can then be filtered to removeimpurities, as described above. Preferred solvents are C₁ to C₄alcohols, particularly methanol. The alcohols used preferably have awater content of less than about 2%, more preferably less than about 1%.

The anti-solvent is then combined with the solution, preferably byadding the solution to the anti-solvent. The anti-solvent is preferablyan ether, wherein each radical of the ether is selected from a C₁ to aC₄ group. Examples of such ethers are di-isopropyl-ether ormethyl-t-butyl-ether. In another embodiment, the anti-solvent is anester, preferably a C₃ to a C₈ ester, such as i-butyl-acetate.

The anti-solvent is preferably vigorously stirred, at a temperature offrom about minus 20° C. to about positive 25° C., preferably from aboutminus 15° C. to about 0° C. Preferably, the solution is added slowly tothe anti-solvent, such as dropwise. The term combining encompasses suchdropwise addition. The resulting mixture can be stirred for about 4 to24 hours. A precipitate forms which can be separated by techniques wellknown in the art. The precipitate can be dried in a fluidized bed dryeror in a vacuum oven at a temperature of about 35° C. As one of skill inthe art can appreciate, other temperatures and conditions can also beused to dry the precipitate.

In an alternative embodiment, amorphous mupirocin calcium is prepared bya process comprising the steps of adding pseudomonic acid, a base and asource of calcium ions to a solvent selected from the group consistingof water, a C₁ to a C₄ alcohol and mixtures thereof to form a solution,and lyophilizing the solution. The amorphous form is lyophilized orfreeze dried out of the solution, entirely skipping any crystallizationor isolation step such as complete solvent removal or addition of ananti-solvent.

For lyophilization, in one embodiment, the solvent used is at leastabout 50% aqueous. The aqueous solvent is preferably water or a mixtureof water and a C₁ to a C₄ alcohol. An exact amount for each component ofthe mixture is not required in the present invention. Rather, themixture should have enough water to be aqueous in character. In oneembodiment, the ratio of the water/solvent mixture is about 1:1 to 1:2(vol/vol). In another embodiment, it is about 3:1 to 4:1 water/solvent.Higher water to solvent ratios are generally preferred. The alcohol ispreferably a C₁ to a C₄ alcohol and most preferably methanol.Theoretically, amorphous mupirocin calcium can be lyophilized from justalcohol, but this process is avoided because of its health risks.

The solution may be modified to obtain a solution having water as asolvent, free of a co-solvent. This modification involves removal ofsolvents other than water, preferably by evaporation. Organic solventssuch as alcohols, especially methanol, often have much higher volatilitythan water. This higher volatility makes it possible to selectivelyevaporate the organic solvent, under either ambient or reduced pressure.Preferably, the pressure is reduced.

The solution may optionally be heated to accelerate the process, thoughit is unnecessary when using high volatile solvents such as methanol.The temperature should not be raised beyond the melting point of theamorphous calcium mupirocin or induce any chemical reactions.

To substantially evaporate the alcohol, some water is probably also lostin the process. Even though water has a lower volatility, itnevertheless evaporates at a sufficient rate to cause loss of water. Thelost water may be replaced, and optionally additional water may be addedbefore freeze drying the solution to obtain the optimal volume forlyophilization.

The solution is lyophilized according to procedures well known in theart. Lyophilization is a stabilizing process in which a substance isfirst frozen and then the quantity of the solvent (generally water) isreduced, first by sublimation (referred to as the primary dryingprocess) and then desorption (known as the secondary drying process) tovalues that will no longer support chemical reactions.

One of skill in the art would appreciate that many factors influence theefficiency of lyophilization and by changing these factors, the obtainedsample may be modified. These factors include: surface area of sample,eutectic temperature, vacuum, condenser temperature, thickness of thesample, solute concentration and instrument factors.

Amorphous form produced by the above process, such as by solventremoval, lyophilization or by use of anti-solvent, can be used to obtainmupirocin calcium dihydrate. Since the amorphous form is already acalcium salt, a neutralization step and the addition of a calcium sourceis unnecessary. The process can simply be carried out in one step, bydissolving amorphous form to form an aqueous solution and crystallizingthe dihydrate from the aqueous solution. For example, amorphousmupirocin calcium prepared by the above process can be dissolved in anethanol/water mixture, followed by removal of the ethanol, andcrystallization from water to recover the dihydrate.

More specifically, amorphous mupirocin calcium can be dissolved in waterto prepare a solution. The temperature can be reduced to about 5° C. toaccelerate crystallization. After about a few days, the crystals areseparated. The dihydrate can be separated by techniques well known inthe art, such as filtration. After separation, the dihydrate can bewashed with water. Preferably, the dihydrate is subsequently dried. Todry, a temperature of about 25° C. to about 50° C. can be used for asufficient amount of time.

In another embodiment for preparing the dihydrate from amorphous form,amorphous mupirocin calcium is dissolved in a water-miscible solvent.Preferably, a C₁ to a C₄ alcohol, such as methanol and ethanol is used.After preparing a solution in a lower alcohol, the solution ispreferably diluted with water. The water content can be increased byremoving the co-solvent, such as by evaporation. Preferably, thedihydrate is recovered by crystallizing out of a solution containingwater free of a co-solvent.

In another aspect, the present invention provides a process forpreparing mupirocin calcium dihydrate comprising the steps of addingpseudomonic acid and calcium oxide to water free of a co-solvent to forma solution, wherein mupirocin calcium dihydrate precipitates from thesolution, separating the mupirocin calcium dihydrate and optionallyconverting the dihydrate to the anhydrate. Pseudomonic acid can besuspended in water. Calcium oxide can then be added to the suspension,followed by stirring and filtering. A co-solvent removal step is notnecessary because a co-solvent is not used. The mixture can be cooled toabout 5° C. and allowed to crystallize. The crystals can be separated bytechniques well known in the art. An air circulating oven at roomtemperature can be used to dry the crystals.

In another aspect, the present invention provides a process forpreparing crystalline mupirocin calcium dihydrate or an anhydratethereof comprising the steps of preparing a solution of pseudomonic acidin a water-immiscible solvent, combining the solution with a solution orsuspension of a calcium C₂ to C₁₂ organic carboxylate in an aqueoussolvent, to form an aqueous and a non-aqueous phase, wherein mupirocincalcium dihydrate precipitates from the aqueous phase, separating theprecipitate and optionally converting the dihydrate to the anhydrate.

Pseudomonic acid is first dissolved in a solvent that is immiscible inwater. A water immiscible solvent refers to a solvent that can form atwo phase system when combined with an aqueous solvent. One of skill inthe art can appreciate that many such solvents exist, and that thepreferred solvent can vary depending on the water content of the aqueoussolvent. Preferred water immiscible solvents are those which pseudomonicacid can dissolve in to form a solution. Preferably, pseudomonic acid isdissolved in a ketone (preferably C₃ to C₈) such as t-butyl methylketone, an ether (preferably water immiscible ethers with each radicalbeing C₁ to C₄) such as methyl t-butyl ether, or an ester (preferablywater immiscible C₃-C₈ esters) such as ethyl acetate. The solvent can beheated to completely dissolve the pseudomonic acid. Preferably, thesolvent is heated of about 40° C. to about 50° C.

After dissolution, an aqueous suspension or solution containing thecalcium salt of an organic carboxylic acid, i.e., calcium carboxylate,is combined with the solution. The process results in an exchange of theacidic proton of pseudomonic acid for the calcium ion of the calciumcarboxylate. In one embodiment, the solvent of the aqueous suspension orsolution is water free of a co-solvent.

The term “organic carboxylic acid” is well-known in the art, and theterm carboxylate refers to its charged ion where the acidic proton hasbeen removed. Fatty acids are examples of organic carboxylic acids. Theorganic carboxylic acid used are branched and straight C₂ to C₁₂carboxylic acids, with acetic, propionic and hexanoic acids beingpreferred, and hexanoic acid being more preferred. More preferably, thecarboxylic acid is an alkylated hexanoic acid such as 2-ethyl-hexanoicacid.

The present invention encompasses embodiments where a calcium source andan organic carboxylate are added separately or when the ions of theorganic calcium carboxylate have either partially or completelydissociated from each other before preparation of the final reactionmixture. The term calcium carboxylate encompasses these embodiment.

After combining the two liquids, a two phase system is created.Preferably, the two phase system is stirred for a few hours to abouthalf a day, followed by separation of the two phases. The non-aqueousphase can be removed. The aqueous phase containing mupirocin calcium canbe extracted with additional water-immiscible solvents to remove anyexcess organic carboxylic acid.

Mupirocin calcium dihydrate is then crystallized out of the aqueousphase. The aqueous phase can be diluted with water beforecrystallization for optimal crystallization. The resulting aqueous layercan be cooled to about 5° C. to accelerate crystallization. Aftercrystallization, the dihydrate can be separated by techniques well-knownin the art, such as filtration. After filtration, the dihydrate canoptionally be washed. The dihydrate can optionally be dried underreduced pressure at slightly elevated temperatures of about 35° C. toremove residual solvents.

In another embodiment, the present invention provides a process forpreparing crystalline mupirocin calcium dihydrate or an anhydratethereof comprising the steps of adding pseudomonic acid and a calcium C₂to C₁₂ organic carboxylate to an aqueous solvent to form a solution,wherein a C₂ to C₁₂ organic carboxylic acid forms, removing thecarboxylic acid, separating mupirocin calcium dihydrate as a precipitatefrom the solvent and optionally converting the dihydrate to theanhydrate.

In one embodiment, pseudomonic acid is dissolved in an aqueous solvent,such as a methanol/water mixture, and is combined with another aqueoussolution containing the calcium carboxylate. Most preferably, thecarboxylate is calcium-2-ethyl-hexanoate. Other co-solvents, such asmethanol, can be removed, preferably by evaporation, to obtain asolution having water as a solvent, free of a co-solvent. Mostpreferably, only a trace of other solvents remains.

After contact, 2-ethyl-hexanoic acid forms. A water-immiscible solvent,such as an ester (ethyl acetate), ether or ketone can be used to extractthe acid, obtaining a two phase system. The aqueous phase is separated,preferably concentrated by evaporation and allowed to crystallize. Afterone or two days of crystallization at about room temperature, thecrystals are separated, preferably by filtration. After separation, thecrystals can optionally be washed with water. The crystals arepreferably dried at a temperature of from about 25° C. to about 50° C.,preferably no more than 45° C.

In another embodiment of the two phase system, the present inventionprovides a process for preparing crystalline mupirocin calcium hydrateor an anhydrate thereof comprising the steps of dissolving pseudomonicacid in a water-immiscible solvent to form a solution, combining thesolution with a solution or suspension of a base and a source of calciumions in an aqueous solvent, to form an aqueous and a non-aqueous phase,wherein the dihydrate precipitates from the aqueous phase, separatingthe dihydrate and optionally converting the dihydrate to the anhydrate.Suitable water immiscible solvents are those as described above.Preferably the solvent of the aqueous solution is water free of aco-solvent, to which a base and a source of calcium ions such as calciumoxide has been added. After mixing, a two phase system forms. Theaqueous layer is separated. Mupirocin calcium dihydrate can then becrystallized out of the aqueous layer as described above, such as bycooling to about 5° C. and allowing for crystallization.

In another aspect, the present invention provides for desolvating thedihydrate to obtain crystalline anhydrous mupirocin calcium (“anhydrateform”). The term “dihydrate” refers to a solvate of water in which twowater molecules (“water of crystallization”) are part of the crystalstructure in the solid phase. Baker et al. discloses that the dihydratecan be desolvated at a temperature of above about 70° C. Or thedihydrate can be dried in the presence of a drying agent such asphosphorus pentoxide, at a temperature range of from about 18° C. to 80°C. for a day. One of skill in the would appreciate that other conditionsand techniques known in the art can also be used to desolvate thedihydrate.

The processes of the present invention can also be described in otherterms, such as reacting pseudomonate ions with calcium ions in solution,and then lyophilizing, removing the solvent or using an anti-solvent toobtain amorphous form.

The PXRD data (FIGS. 1-5) disclosed further confirms the result of theprocesses. The PXRD data shows a pattern for the mupirocin calciumdihydrate.

The following table, Table 3, illustrates the purity data for thesamples from the examples. The purity data in the table are areapercentages and not assays.

TABLE 3 Purity of mupirocin calcium dihydrate Example # MupirocinCalcium Dihydrate Area % (Not Assay) 9 98 10 98.2 11 97.5 13 97.8 1697.6

Many processes of the present invention involve crystallization out of aparticular solvent. One of skill in the art would appreciate that theconditions concerning crystallization may be modified without affectingthe form of the polymorph obtained. For example, when mixing a solute ina solvent to form a solution, warming of the mixture may be necessary tocompletely dissolve the starting material. If warming does not clarifythe mixture, the mixture may be diluted or filtered. To filter, the hotmixture may be passed through paper, glass fiber or other membranematerial, or a clarifying agent such as celite. Depending upon theequipment used and the concentration and temperature of the solution,the filtration apparatus may need to be preheated to avoid prematurecrystallization.

The conditions may also be changed to induce or accelerateprecipitation. A preferred way of inducing crystallization is to reducethe solubility of the solvent. The solubility of the solvent may bereduced, for example, by cooling the solvent.

Another manner to accelerate crystallization is by seeding with acrystal of the product or scratching the inner surface of thecrystallization vessel with a glass rod. Other times, crystallizationmay occur spontaneously without any inducement. The present inventioncovers both embodiments where crystallization is induced/accelerated oroccurs spontaneously. A separate crystallization step is not recited toemphasize that crystallization can occur spontaneously, but suchemphasis is not meant to change the scope of the present invention fromone reciting a crystallization step. One of skill in the art wouldappreciate that the conditions provided for crystallization in thepresent invention are for illustration, and that their modification maynot necessarily change the result.

Pharmaceutical Compositions Containing Highly Purified Amorphous CalciumMupirocin

In accordance with the present invention, the highly pure calciummupirocin, including the amorphous form, are prepared by the new methodsdisclosed herein. They may be prepared as pharmaceutical compositionsthat are particularly useful for the treatment of infections,particularly secondarily infected traumatic skin lesions. Suchcompositions comprise calcium mupirocin, such as the amorphous form,with pharmaceutically acceptable carriers and/or excipients known to oneof skill in the art.

For example, these compositions may be prepared as medicaments to beadministered orally, parenterally, rectally, transdermally, bucally, ornasally. Suitable forms for oral administration include tablets,compressed or coated pills, dragees, sachets, hard or gelatin capsules,sub-lingual tablets, syrups and suspensions. Suitable forms ofparenteral administration include an aqueous or anhydrous solution oremulsion, while for rectal administration suitable forms foradministration include suppositories with hydrophilic or hydrophobicvehicle. For topical administration the invention provides suitabletransdermal delivery systems known in the art or formulations thatsubstantially remain local for topical use, and for nasal delivery thereare provided suitable aerosol delivery systems known in the art.

The topical compositions of the present invention may be made as taughtby the prior art. U.S. Pat. No. 4,879,287 is incorporated herein for thecomposition of a topical cream. The composition comprises preferablyless than 50% active ingredient. More preferably less than 10% and mostpreferably about 2%. The composition may be administered with acorticosteroid content of less than about 5%, most preferably less thanabout 2%. U.S. Pat. No. 4,879,287 can be consulted for a fulldescription of requirements for a topical cream. Bactroban® can also beused for guidance.

Pharmaceutical compositions of the present invention contain highlypurified calcium mupirocin, including the amorphous form, optionally inmixture with other forms of mupirocin. In addition to the activeingredient(s), the pharmaceutical compositions of the present inventionmay contain one or more excipients. Excipients are added to thecomposition for a variety of purposes.

Diluents increase the bulk of a solid pharmaceutical composition and maymake a pharmaceutical dosage form containing the composition easier forthe patient and care giver to handle. Diluents for solid compositionsinclude, for example, microcrystalline cellulose (e.g. Avicel®),microfine cellulose, lactose, starch, pregelitinized starch, calciumcarbonate, calcium sulfate, sugar, dextrates, dextrin, dextrose, dibasiccalcium phosphate dihydrate, tribasic calcium phosphate, kaolin,magnesium carbonate, magnesium oxide, maltodextrin, mannitol,polymethacrylates (e.g. Eudragit®), potassium chloride, powderedcellulose, sodium chloride, sorbitol and talc.

Solid pharmaceutical compositions that are compacted into a dosage formlike a tablet may include excipients whose functions include helping tobind the active ingredient and other excipients together aftercompression. Binders for solid pharmaceutical compositions includeacacia, alginic acid, carbomer (e.g. carbopol), carboxymethylcellulosesodium, dextrin, ethyl cellulose, gelatin, guar gum, hydrogenatedvegetable oil, hydroxyethyl cellulose, hydroxypropyl cellulose (e.g.Klucel®), hydroxypropyl methyl cellulose (e.g. Methocel®), liquidglucose, magnesium aluminum silicate, maltodextrin, methylcellulose,polymethacrylates, povidone (e.g. Kollidon®, Plasdone®), pregelatinizedstarch, sodium alginate and starch.

The dissolution rate of a compacted solid pharmaceutical composition inthe patient's stomach may be increased by the addition of a disintegrantto the composition. Disintegrants include alginic acid,carboxymethylcellulose calcium, carboxymethylcellulose sodium (e.g.Ac-Di-Sol®, Primellose®), colloidal silicon dioxide, croscarmellosesodium, crospovidone (e.g. Kollidon®, Polyplasdone®), guar gum,magnesium aluminum silicate, methyl cellulose, microcrystallinecellulose, polacrilin potassium, powdered cellulose, pregelatinizedstarch, sodium alginate, sodium starch glycolate (e.g. Explotab®) andstarch.

Glidants can be added to improve the flowability of non-compacted solidcomposition and improve the accuracy of dosing. Excipients that mayfunction as glidants include colloidal silicon dixoide, magnesiumtrisilicate, powdered cellulose, starch, talc and tribasic calciumphosphate.

When a dosage form such as a tablet is made by compaction of a powderedcomposition, the composition is subjected to pressure from a punch anddye. Some excipients and active ingredients have a tendency to adhere tothe surfaces of the punch and dye, which can cause the product to havepitting and other surface irregularities. A lubricant can be added tothe composition to reduce adhesion and ease release of the product formthe dye. Lubricants include magnesium stearate, calcium stearate,glyceryl monostearate, glyceryl palmitostearate, hydrogenated castoroil, hydrogenated vegetable oil, mineral oil, polyethylene glycol,sodium benzoate, sodium lauryl sulfate, sodium stearyl fumarate, stearicacid, talc and zinc stearate.

Flavoring agents and flavor enhancers make the dosage form morepalatable to the patient. Common flavoring agents and flavor enhancersfor pharmaceutical products that may be included in the composition ofthe present invention include maltol, vanillin, ethyl vanillin, menthol,citric acid, fumaric acid, ethyl maltol, and tartaric acid.

Solid and liquid compositions may also be dyed using anypharmaceutically acceptable colorant to improve their appearance and/orfacilitate patient identification of the product and unit dosage level.

In liquid pharmaceutical compositions of the present invention, theamorphous calcium mupirocin and any other solid excipients are dissolvedor suspended in a liquid carrier such as water, vegetable oil, alcohol,polyethylene glycol, propylene glycol or glycerin.

Liquid pharmaceutical compositions may contain emulsifying agents todisperse uniformly throughout the composition an active ingredient orother excipient that is not soluble in the liquid carrier. Emulsifyingagents that may be useful in liquid compositions of the presentinvention include, for example, gelatin, egg yolk, casein, cholesterol,acacia, tragacanth, chondrus, pectin, methyl cellulose, carbomer,cetostearyl alcohol and cetyl alcohol.

Liquid pharmaceutical compositions of the present invention may alsocontain a viscosity enhancing agent to improve the mouth-feel of theproduct and/or coat the lining of the gastrointestinal tract. Suchagents include acacia, alginic acid bentonite, carbomer,carboxymethylcellulose calcium or sodium, cetostearyl alcohol, methylcellulose, ethylcellulose, gelatin guar gum, hydroxyethyl cellulose,hydroxypropyl cellulose, hydroxypropyl methyl cellulose, maltodextrin,polyvinyl alcohol, povidone, propylene carbonate, propylene glycolalginate, sodium alginate, sodium starch glycolate, starch tragacanthand xanthan gum.

Sweetening agents such as sorbitol, saccharin, sodium saccharin,sucrose, aspartame, fructose, mannitol and invert sugar may be added toimprove the taste.

Preservatives and chelating agents such as alcohol, sodium benzoate,butylated hydroxy toluene, butylated hydroxyanisole and ethylenediaminetetraacetic acid may be added at levels safe for ingestion to improvestorage stability.

A liquid composition according to the present invention may also containa buffer such as guconic acid, lactic acid, citric acid or acetic acid,sodium guconate, sodium lactate, sodium citrate or sodium acetate.

Selection of excipients and the amounts to use may be readily determinedby the formulation scientist based upon experience and consideration ofstandard procedures and reference works in the field.

The solid compositions of the present invention include powders,granulates, aggregates and compacted compositions. The dosages includedosages suitable for oral, buccal, rectal, parenteral (includingsubcutaneous, intramuscular, and intravenous), inhalant and ophthalmicadministration. The dosages may be conveniently presented in unit dosageform and prepared by any of the methods well-known in the pharmaceuticalarts.

Dosage forms include solid dosage forms like tablets, powders, capsules,suppositories, sachets, troches and losenges as well as liquid syrups,suspensions and elixirs.

An dosage form of the present invention is a capsule containing thecomposition, preferably a powdered or granulated solid composition ofthe invention, within either a hard or soft shell. The shell may be madefrom gelatin and optionally contain a plasticizer such as glycerin andsorbitol, and an opacifying agent or colorant.

The active ingredient and excipients may be formulated into compositionsand dosage forms according to methods known in the art.

A composition for tableting or capsule filing may be prepared by wetgranulation. In wet granulation some or all of the active ingredientsand excipients in powder form are blended and then further mixed in thepresence of a liquid, typically water, that causes the powders to clumpup into granules. The granulate is screened and/or milled, dried andthen screened and/or milled to the desired particle size. The granulatemay then be tableted or other excipients may be added prior to tabletingsuch as a glidant and or lubricant.

A tableting composition may be prepared conventionally by dry blending.For instance, the blended composition of the actives and excipients maybe compacted into a slug or a sheet and then comminuted into compactedgranules. The compacted granules may be compressed subsequently into atablet.

As an alternative to dry granulation, a blended composition may becompressed directly into a compacted dosage form using directcompression techniques. Direct compression produces a more uniformtablet without granules. Excipients that are particularly well suited todirect compression tableting include microcrystalline cellulose, spraydried lactose, dicalcium phosphate dihydrate and colloidal silica. Theproper use of these and other excipients in direct compression tabletingis known to those in the art with experience and skill in particularformulation challenges of direct compression tableting.

A capsule filling of the present invention may comprise any of theaforementioned blends and granulates that were described with referenceto tableting, only they are not subjected to a final tableting step.

A single oral dose of 500 mg base equivalent has been well tolerated andone of skill in the art may design capsules, tablets and lozenges andother unit dosage forms accordingly.

Characterization data was obtained in the following manner:

Thermal Stability

Glass ampoule in Aluminum laminate bag with silica gel was used as thepacking system. Relative humidity was exactly 60%.

Water Content

The water content was measured by the Karl Fischer method.

Powder X-Ray Diffraction

Instrument—Scintag X'TRA-030 X-ray diffractometer.

Software—DMSNT.

Radiation source was Copper (FK61-10CU).X-ray Generator Model-20×2988, operated at 45 KV and 40 mA.Detector—solid state.Data was acquired with a scan rate of 3.00 Deg./min. at a range of 4-40.Degree, step size 0.050°, Cnt time 1 sec.

DSC Mettler TA 3000, DSC 20

heating interval—25-250° C.heating rate—5° C./min.atmosphere—Nitrogen, 40 ml/min.sample holder—Al crucible with holes

TG Mettler TA 3000, TG 50

heating interval—25-250° C.heating rate—5° C./min.atmosphere—Nitrogen, 40 ml/min.sample holder—Ceramic 150 ml

IR Perkin Elmer FTIR SPECTRUM 1000

Spectra was taken in KBr pellet in the range of 4000-400 cm⁻¹

Determination of Impurities for Mupirocin-Calcium

High pressure liquid chromatography (HPLC) was performed on a Zorbax®C-8 (5 um; 250×4.6 mm), reverse phase column with ammonium acetatebuffer solution in water: tetrahydrofuran mixture as eluent. Detected byU.V. spectroscopy at λ=240 nm.

Determination of Impurities for Pseudomonic Acid

High pressure liquid chromatography (HPLC) was performed on a HypersilShandan BDS® C-18 (3 um; 100×4.6 mm), reverse phase column withsodium-dihydrogen-phosphate buffer solution in water:acetonitrilemixture as gradient eluent. Detected by U.V. spectroscopy at λ=229 nm.

The assay also used the same HPLC instruments.

EXAMPLES Example 1 Preparation of Mupirocin Calcium Dihydrate

Amorphous mupirocin calcium (2.50 g, 2.40 mmole) was dissolved in water(10 ml) and stirred to give a clear solution. The mupirocin calciumsolution was allowed to crystallize for 60 h at 5° C. The crystallineproduct was filtered and washed with water (5 ml). The crystallineproduct was dried at 45° C. for 6 h.

Example 2 Preparation of Mupirocin Calcium Dihydrate

Amorphous mupirocin calcium (5.00 g, 4.80 mmole) was dissolved inmethanol (15 ml) and stirred to give a clear solution. Water (10 ml) wasadded to the solution. Methanol from the solution was evaporated atreduced pressure to give a final volume of 7 ml. The mupirocin calciumsolution was allowed to crystallize for 60 h at 5° C. The crystallineproduct was filtered and washed with water (5 ml). The product was driedat 30° C. for 12 h.

Example 3 Preparation of Mupirocin Calcium Dihydrate

Pseudomonic acid (2.50 g, 10 mmole) was dissolved in a mixture ofmethanol and water (30 ml and 30 ml). Calcium 2-ethyl-hexanoate (0.92 g,5.00 mmole) was dissolved in a mixture of methanol and water (60 ml and30 ml). The calcium 2-ethyl-hexanoate solution was added to thepseudomonic acid solution, and stirred for 1 h. The methanol wasevaporated from the solution at reduced pressure to give a final volumeof 60 ml. The 2-ethyl hexanoic acid was extracted with ethyl-acetate(2×40 ml), and the aqueous layer was evaporated from the solution atreduced pressure to give a final volume of 50 ml. The mupirocin calciumsolution was allowed to crystallize for 36 h at room temperature. Thecrystalline product was filtered and washed with water (10 cm³). Theproduct was dried at 40° C. for 8 h.

Example 4 Preparation of Amorphous Mupirocin Calcium

Pseudomonic acid (4000 g, 8 mole) was dissolved in ethanol (10 l).Ethanolic solution of potassium hydroxide (448.88 g, 8 mole potassiumhydroxide and 2.6:1 ethanol) and ethanolic solution of calcium chloride(443.96 g, 5.0 mmole calcium chloride and 2.6:1 ethanol) was added tothe mixture. The mixture was stirred for 90 minutes and then filtered toremove potassium chloride. Then, 3:1 ethanol was added to the solutionand the ethanol was evaporated at reduced pressure to give a finalvolume of 10:1 (Solution A). Ethanol was evaporated from 1400 ml ofSolution A with rotary evaporation at reduced pressure to give a solid,white foam. The product was dried for 12 h at 45° C. under vacuum.

Example 5 Preparation of Mupirocin Calcium Dihydrate

Water (20 ml) was added to a mupirocin calcium ethanolic concentrate(50.84 g, ca. 37 m/m %) prepared generally by the same technique as theprior example. The ethanol from the solution was evaporated at reducedpressure to give a final volume of 20 ml. The mupirocin calcium solutionwas allowed to crystallize for 24 h at 5° C. The crystalline product wasfiltered and washed with water (15 ml). The product was dried at 30° C.for 12 h.

The water from the filtrate was evaporated at reduced pressure to give afinal volume of 5 ml. The mupirocin calcium solution was allowed tocrystallize for 24 h at 5° C. The crystalline product was filtered andwashed with water (2×15 ml). The product was dried at 30° C. for 12 h.

Example 6 Preparation of Mupirocin Calcium Dihydrate

Pseudomonic acid (10 g) was suspended in water (26 ml). Calcium oxide(0.58 g) was added to the suspension. The mixture was stirred for onehour, and filtered. The mixture was cooled to 5° C. After standing for15 h, the crystalline product was filtered and washed with cooled water(10 ml) and dried in an air circulated oven at room temperature.Mupirocin calcium dihydrate (9.4 g, 87%) was obtained.

PXRD confirmation data attached (FIG. 1).

Example 7 Preparation of Mupirocin Calcium Dihydrate

Amorphous mupirocin calcium (14 g) was dissolved in water (35 ml) andstirred for one hour. The mixture was cooled to 5° C. and kept at thistemperature for 15 hours. Then mixture was then stirred at 5° C. for 3hours. The crystalline product was filtered and dried in an aircirculated oven at room temperature. Mupirocin calcium dihydrate (12.5g, 83%) was obtained.

Example 8 Preparation of Mupirocin Calcium Dihydrate

Amorphous mupirocin calcium (20.00 g, 19.20 mmole) was added into water(20 ml) under stirring. The slurry was stirred for 0.5 hour, and then itwas cooled to 5° C. The mupirocin calcium solution was allowed tocrystallize for 16 h. The crystal slurry was diluted with 15 ml water,and the crystals were filtered and washed with water (5 ml). The product(17.1 g) was dried at 35° C. for 12 h.

Example 9 Preparation of Mupirocin Calcium Dihydrate

Pseudomonic acid (10 g) was dissolved in isobutyl methyl ketone (120ml). Calcium oxide (0.57 g) was suspended in water (68 ml), and added tothe solution of pseudomonic acid. The mixture was stirred for one hour,and the phases were separated. The volume of the aqueous phase wasreduced to 40 ml by vacuum distillation. The mixture was cooled to 5°C., and after standing for 15 hours, the crystalline product wasfiltered and washed with cooled water (10 ml). The product was thendried in an air circulated oven at RT. Mupirocin calcium dihydrate (3.7g, 35%) was obtained.

PXRD confirmation data is attached (FIG. 2).

Example 10 Preparation of Mupirocin Calcium Dihydrate

Pseudomonic acid (10.00 g, 20 mmole) was dissolved in 100 ml of ethylacetate at 40° C. Calcium-2-ethyl-hexanoate (3.32 g, 10 mmole) wassuspended in 25 ml of water. The solution of pseudomonic acid was addedto the calcium-2-ethyl-hexanoate suspension, and the resulting twophases system were stirred for 14 hours. The two phases were thenseparated, and any traces of ethyl acetate was evaporated from theaqueous phase. The aqueous mupirocin calcium suspension was cooled inthe refrigerator to 5° C. and precipitated. The solid mupirocin calciumdihydrate was subsequently filtered, washed with 10 ml water and driedunder vacuum at 35° C. for 14 hours. The mass of the product was 7.82grams.

PXRD confirmation data is attached. (FIG. 3).

Example 11 Preparation of Mupirocin Calcium Dihydrate

Pseudomonic acid (10.00 g, 20 mmole) was dissolved in methyl tertbutylether (150 ml) at 45° C. Calcium-2-ethyl-hexanoate (3.32 g, 10 mmole)was suspended in water (30 ml). The solution of pseudomonic acid wasadded to the calcium-2-ethyl-hexanoate suspension, and the resulting twophases system were stirred for 14 hours. The two phases were thenseparated, and water (20 ml) and methyl tertbutyl ether (50 ml) wasadded to the aqueous phase, and was stirred for 10 minutes. Theresulting two phases were separated, and any traces of methyl tertbutylether was evaporated from the aqueous phase. The aqueous mupirocincalcium suspension was cooled in a refrigerator at 5° C. The solidmupirocin calcium dihydrate was filtered, washed with 20 ml water anddried under vacuum at 35° C. for 5 hours. The mass of product was 5.88grams.

Example 12 Preparation of Mupirocin Calcium Dihydrate

Pseudomonic acid (10.00 g, 20 mmole) was dissolved in methyl tertbutylether (180 ml) at 40° C. Calcium-2-ethyl-hexanoate (3.32 g, 10 mmole)was suspended in water (50 ml). (It is possible to obtain a solution byusing a larger amount of water or an alcohol/water mixture). Thesolution of pseudomonic acid was added to the calcium-2-ethyl-hexanoatesuspension, and the two phase system was stirred for 24 hours. The twophases were separated, 50 ml methyl tertbutyl ether was added to theaqueous phase and stirred for 10 minutes. The two resulting phases wereseparated, and the methyl tertbutyl ether was evaporated from theaqueous phase. The aqueous mupirocin calcium suspension was cooled inthe refrigerator at 5° C. The solid mupirocin calcium dihydrate wasfiltered, washed with water (20 ml) and dried under vacuum at 35° C. for14 hours. The mass of product was 8.65 grams. Assay: 95.68%, water:3.48%

Example 13 Preparation of Mupirocin Calcium Dihydrate

Pseudomonic acid (10.00 g, 20 mmole) was dissolved in isobutyl methylketone (100 ml) at 40° C. Calcium-2-ethyl-hexanoate (3.32 g, 10 mmole)was suspended in water (50 ml). (It is possible to obtain a solution byusing a larger amount of water or an alcohol/water mixture). Thesolution of pseudomonic acid was added to the calcium-2-ethyl-hexanoatesuspension, and the two phase system were stirred for 24 hours. The twophases were then separated, isobutyl methyl ketone (25 ml) was added tothe aqueous phase, and stirred for 10 minutes. The two resulting phaseswere separated, and any traces of isobutyl methyl ketone was evaporatedfrom the aqueous phase. The aqueous mupirocin calcium suspension wascooled in a refrigerator at 5° C. The solid mupirocin calcium dihydratewas filtered, washed with water (20 ml) and dried under vacuum at 35° C.for 14 hours. The mass of product was 7.95 grams. Assay 97.72%, water:3.45%.

Example 14 Preparation of Mupirocin Calcium Dihydrate

Pseudomonic acid (10.00 g, 20 mmole) was dissolved in a mixture ofmethanol (30 ml) and water (15 ml). Calcium 2-ethyl-hexanoate (3.32 g,10.00 mmole) was dissolved in a mixture of methanol (60 ml) and water(30 ml). The calcium 2-ethyl-hexanoate solution added to the pseudomonicacid solution and was stirred for 1 h. The methanol was evaporated fromthe solution at reduced pressure to give a final volume of 45 ml. Water(15 ml) was added from the solution. The 2-ethyl hexanoic acid wasextracted with ethyl-acetate (3×20 ml) and the aqueous layer wasevaporated from the solution at reduced pressure to give a final volumeof 60 ml. The mupirocin calcium solution was allowed to crystallize for36 h at 5° C. temperature. The crystalline product was filtered andwashed with water (10 ml). The product (3.6 g) was dried at 35° C. for 8h.

Assay: 96.9% Water: 3.0%

(This assay is expressed differently than those for amorphous form.Table-1 should be consulted in regard to this matter).

Example 15 Preparation of Mupirocin Calcium Dihydrate

Pseudomonic acid (50.00 g, 0.10 mole) was dissolved in methanol (150ml). Calcium 2-ethyl-hexanoate (15.92 g, 48.00 mmole) was suspended in amixture of methanol/water (250 ml and 125 ml). The pseudomonic acidsolution added to the calcium 2-ethyl-hexanoate solution and was stirredfor 1 h. The methanol was evaporated from the solution at reducedpressure to give a final volume of 125 ml. The 2-ethyl hexanoic acid wasextracted with ethyl-acetate (4×50 ml), and the aqueous layer wasevaporated from the solution at reduced pressure to give a final volumeof 125 ml. The mupirocin calcium solution was allowed to crystallize for48 h at 5° C. temperature. The crystalline product was filtered andwashed with water (10 ml). The product (18.4 g) was dried at 35° C. for8 h.

PXRD confirmation data is attached. (FIG. 4)

Example 16 Preparation of Mupirocin Calcium Dihydrate

Pseudomonic acid was dissolved in isobutyl acetate (130 ml). Calciumoxide (0.29 g) was suspended in water (32 ml) and added to the solutionof pseudomonic acid. The mixture was stirred for 2 hours, and the phaseswere separated. The volume of the aqueous phase was reduced to 15 ml byvacuum distillation. The mixture was cooled to 5° C. After stirring for2 hours, the crystalline product was filtered and washed with cooledwater (5 ml). The product was dried in an air circulated oven at RT.Mupirocin calcium dihydrate (3.3 g, 62%) was obtained.

Example 17 Preparation of Amorphous Mupirocin Calcium

Pseudomonic acid (5.00 g, 10 mmole) was dissolved in methanol (5.5 ml),methanolic solution of potassium hydroxide (0.56 g, 10 mmole potassiumhydroxide and 4 ml methanol) and methanolic solution of calcium chloride(0.56 g, 5.0 mmole calcium chloride and 5 ml methanol) were added to themixture. The mixture was stirred for 1 hour. The solution was thenfiltered to remove potassium chloride (0.60 g). The methanol was thenevaporated at reduced pressure to give a solid, white foam. The productwas dried for 12 hours at 45° C. under vacuum to obtain 4.85 grams offinal product. Assay: 95.9%, Water: 2.23% [total impurity: 3.19%,highest impurity: 1.23%—different method than assay], melting point: 85to 89° C.

Example 18 Preparation of Amorphous Mupirocin Calcium

Pseudomonic acid (5.00 g, 10 mmole) was dissolved in ethanol (20 ml),ethanolic solution of potassium hydroxide (0.56 g, 10 mmole potassiumhydroxide and 10 ml ethanol) and ethanolic solution of calcium chloride(0.56 g, 5.0 mmole calcium chloride and 10 ml ethanol) were added to themixture. The mixture was stirred for 1 hour and the solution wasfiltered to remove potassium chloride (0.51 g). The ethanol wassubsequently evaporated at reduced pressure to give a solid, white foam.The product was dried for 12 hours at 45° C. under vacuum. The producthad a mass of 4.38 grams. Assay: 99.1%, water: 2.36% [total impurity:2.44%, highest impurity: 1.10% different method than the assay].

Example 19 Preparation of Amorphous Mupirocin Calcium

Pseudomonic acid (4000 g, 8 mole) was dissolved in ethanol (10 l),ethanolic solution of potassium hydroxide (448.88 g, 8 mole potassiumhydroxide and 2.6:1 ethanol) and ethanolic solution of calcium chloride(443.96 g, 5.0 mmole calcium chloride and 2.6:1 ethanol) were added tothe mixture. The mixture was stirred for 90 minutes, and the solutionwas filtered to remove potassium chloride. Ethanol was added to thesolution in a 1:3 ratio, and the ethanol was evaporated at reducedpressure to give a final volume of 10:1 (Solution A).

Ethanol was evaporated from Solution A (350 ml) with a rotaryevaporation at reduced pressure to give a solid, white foam. The productwas dried for 12 hours at 45° C. under vacuum to give a final productwith a mass of 110.02 grams.

Assay: 98.2%, water 0.36%, melting point: 84-86° C.

Ethanol was evaporated from 1400 ml of Solution A with a rotaryevaporation at reduced pressure to give a solid, white foam. The productwas dried for 12 h at 45° C. under vacuum to give a mass of 513.18grams.

Assay: 96.8% [total impurity: 3.66%, highest impurity: 1.29%—differentmethod than the assay], melting point: 85-86° C.

Example 20 Preparation of Amorphous Mupirocin Calcium

Pseudomonic acid (220 g) was dissolved in methanol (210 ml) kept at25-27° C. Separately, potassium hydroxide (27.9 g) was dissolved inmethanol (154 ml). Also separately, calcium chloride (24.39 g) wasdissolved in methanol (133 ml). The potassium hydroxide solution wasadded to the pseudomonic acid solution until obtaining a pH=9.4-9.5 (147ml of potassium hydroxide solution was added.). The calcium chloridesolution was then added to the mupirocin potassium solution untilreaching a pH=7.6-7.7 (128 ml of calcium chloride solution was added.).The solution was stirred at 24-25° C. for an hour. Potassium chloridewas filtered, and the solution was labeled Solution B. Solution B (25ml) was added to diisopropyl-ether (250 ml) at (−7° C. while stirring.Solid amorphous mupirocin calcium precipitated from the solution, andwas stirred at −7° C. for 3 h. The solid product was filtered and washedwith cold diisopropyl-ether (10 ml). The product was dried in afluidized bed dryer for 6 hours at 35° C., and then in a vacuum oven for12 h at 35° C.

Example 21 Preparation of Amorphous Mupirocin Calcium by Lyophilization

Pseudomonic acid (10.01 g, 20 mmole) was dissolved in a mixture ofmethanol/water (50 ml and 36 ml). Calcium oxide (0.78 g, 14 mmole) wasadded portionwise to the mixture and was stirred for 1 h. The solutionwas filtered, and the methanol was evaporated from the filtrate atreduced pressure to give a final volume of 30 ml. Water (20 ml) wasadded to the solution. Then the solution was freeze dried to obtain 9.11grams of product.

Assay: 100%, water: 1.59%, melting point: 84-86° C., [total impurity:2.64%, highest impurity: 1.35%—different method than the assay], meltingpoint: 84-86° C.

Having thus described the invention with reference to particularpreferred embodiments and illustrated it with examples, those in the artcan appreciate modifications to the invention as described andillustrated that do not depart from the spirit and scope of theinvention as disclosed in the specification. The Examples are set forthto aid in understanding the invention but are not intended to, andshould not be construed to, limit its scope in any way. The examples donot include detailed descriptions of conventional methods. Such methodsare well known to those of ordinary skill in the art and are describedin numerous publications. Detailed descriptions of conventional methodsrelating to solid state chemistry are discussed in Polymorphism inPharmaceutical Solids, Drugs and the Pharmaceutical Sciences, vol. 95.All references mentioned herein are incorporated in their entirety.

1. A process for preparing crystalline mupirocin calcium dihydrate or ananhydrate thereof comprising the steps of: a) preparing a solution ofpseudomonic acid in a water-immiscible solvent; b) combining thesolution with a suspension or solution of a calcium C₂ to C₁₂ organiccarboxylate in an aqueous solvent, to form an aqueous phase and anon-aqueous phase, wherein mupirocin calcium dihydrate precipitates fromthe aqueous phase; c) separating the precipitate; and d) optionallyconverting the dihydrate to the anhydrate.
 2. The process of claim 1,wherein the aqueous solvent is water free of a co-solvent.
 3. Theprocess of claim 1, wherein the aqueous solvent is a mixture of waterand a C₁ to a C₄ alcohol.
 4. The process of claim 1, wherein the organiccarboxylate is 2-ethyl-hexanoate.
 5. A process for preparing crystallinemupirocin calcium dihydrate or an anhydrate thereof comprising the stepsof: a) adding pseudomonic acid and a calcium C₂ to C₈ organiccarboxylate to an aqueous solvent to form a solution, wherein a C₂ to C₈organic carboxylic acid forms; b) removing the carboxylic acid; c)separating the mupirocin calcium dihydrate as a precipitate from theaqueous solvent; and d) optionally converting the dihydrate to theanhydrate.
 6. The process of claim 5, wherein the aqueous solvent is amixture of water and a C₁ to a C₄ alcohol.
 7. The process of claim 6,further comprising a step of increasing the water content of the aqueoussolvent before step (c).
 8. The process of claim 5, wherein the removingstep is carried out by extraction.
 9. The process of claim 5, whereinthe organic carboxylate is 2-ethyl-hexanoate.
 10. A process forpreparing crystalline mupirocin calcium dihydrate or an anhydratethereof comprising the steps of: a) adding pseudomonic acid and calciumoxide to water free of a co-solvent to form a solution, whereinmupirocin calcium dihydrate precipitates from the solution; b)separating the mupirocin calcium dihydrate; and c) optionally convertingthe dihydrate to the anhydrate.
 11. A process for preparing amorphousmupirocin calcium comprising the steps of: a) adding pseudomonic acid, abase, and a source of calcium ions to a C₁ to a C₄ alcohol to form asolution; and b) removing the alcohol.
 12. The process of claim 11,wherein the alcohol is substantially anhydrous.
 13. The process of claim12, wherein the alcohol has less than about 1% (vol/vol) water content.14. The process of claim 11, wherein the alcohol is selected from thegroup consisting of methanol and ethanol.
 15. The process of claim 11,wherein the removing step is carried out by evaporating the alcohol. 16.A process for preparing amorphous mupirocin calcium comprising the stepsof: a) adding pseudomonic acid, a base and a source of calcium ions to aC₁ to a C₄ alcohol to form a solution; b) combining the solution with ananti-solvent to precipitate amorphous mupirocin calcium; and c)separating the precipitate.
 17. The process of claim 16, wherein thealcohol has less than about 1% (vol/vol) water content.
 18. The processof claim 16, wherein the alcohol is selected from the group consistingof ethanol and methanol.
 19. The process of claim 16, wherein theanti-solvent is selected from the group consisting of esters and ethers.20. The process of claim 19, wherein the anti-solvent as an ether isselected from the group consisting of methyl-t-butyl ether anddiisopropylether.
 21. The process of claim 19, wherein the anti-solventas an ester is i-butyl acetate.
 22. The process of claim 16, whereincombining is carried out by adding the solution to the anti-solvent. 23.A process for preparing amorphous mupirocin calcium comprising the stepsof: a) adding pseudomonic acid, a base and a source of calcium ions to asolvent selected from the group consisting of water, a C₁ to a C₄alcohol, or mixtures thereof to form a solution; and b) lyophilizing thesolution.
 24. The process of claim 23, wherein the alcohol is methanol.25. The process of claim 23, further comprising a step, before thelyophilization step, of removing solvents other than water andoptionally adding water.
 26. A process for preparing crystallinemupirocin calcium hydrate or an anhydrate thereof comprising the stepsof: a) dissolving pseudomonic acid in a water-immiscible solvent to forma solution; b) combining the solution with a suspension or solution of abase and a source of calcium ions in an aqueous solvent, to form anaqueous and a non-aqueous phase, wherein mupirocin calcium dihydrateprecipitates from the aqueous phase; c) separating the dihydrate; and d)optionally converting the dihydrate to the anhydrate.
 27. The process ofclaim 26, wherein the water-immiscible solvent is selected from thegroup consisting of esters and ketones.
 28. The process of claim 27,wherein the water-immiscible solvent as an ester selected is iso-butylacetate.
 29. The process of claim 27, wherein the water-immisciblesolvent as a ketone is isobutyl methyl ketone.
 30. A process forpreparing crystalline mupirocin calcium dihydrate comprising the stepsof: a) adding pseudomonic acid, a base and a source of calcium ions to aC₁ to a C₄ alcohol to form a solution; b) adding the solution to anether or an ester as an anti-solvent to precipitate amorphous mupirocincalcium; c) dissolving the amorphous mupirocin calcium in a solventselected from the group consisting of water, and a mixture of water anda C₁ to a C₄ alcohol to form a solution, wherein the dihydrateprecipitates from the solution; and d) separating the dihydrate.
 31. Aprocess for preparing crystalline mupirocin calcium dihydrate comprisingthe steps of: a) adding pseudomonic acid, a base and a source of calciumions to a C₁ to a C₄ alcohol to form a solution; b) evaporating thealcohol to obtain amorphous mupirocin calcium; c) dissolving theamorphous mupirocin calcium in a solvent selected from the groupconsisting of water, and a mixture of water and a C₁ to a C₄ alcohol toform a solution, wherein the dihydrate precipitates from the solution;and d) separating the dihydrate.
 32. A process for preparing crystallinemupirocin calcium dihydrate comprising the steps of: a) addingpseudomonic acid, a base and a source of calcium ions to a solventselected from the group consisting of water, and a mixture of water anda C1 to a C4 alcohol to form a solution; b) lyophilizing the solution toobtain amorphous mupirocin calcium; c) dissolving the amorphousmupirocin calcium in a solvent selected from the group consisting ofwater and a mixture of water and a C₁ to a C₄ alcohol to precipitate thedihydrate; and d) separating the dihydrate as a precipitate.
 33. Aprocess for preparing amorphous mupirocin calcium comprising the stepsof: a) reacting pseudomonate ions and calcium ions in solution in a C₁to a C₄ alcohol; and b) evaporating the alcohol.
 34. A process forpreparing amorphous mupirocin calcium comprising the steps of: a)reacting pseudomonate ions and calcium ions in solution in a C1 to a C4alcohol; b) adding the solution to an ester or an ether as ananti-solvent to precipitate amorphous mupirocin calcium; and c)separating the precipitate.
 35. A process for preparing amorphousmupirocin calcium comprising the steps of: a) reacting pseudomonate ionsand calcium ions in solution in a solvent selected from the groupconsisting of water and a mixture of water and a C₁ to a C₄ alcohol; andb) lyophilizing the solution.
 36. A process for preparing crystallinemupirocin calcium dihydrate or an anhydrate thereof comprising the stepsof: a) providing pseudomonic acid and a calcium C₂ to C₁₂ organiccarboxylate; b) exchanging acidic proton of the pseudomonic acid withthe calcium of the C₂ to C₁₂ organic carboxylate; c) recovering themupirocin calcium dihydrate; and d) optionally converting the dihydrateto the anhydrate. 37-44. (canceled)
 45. The process of claim 11, 12, 31or 33, further comprising the step of drying amorphous form.
 46. Theprocess of claim 31 or 33, wherein the alcohol is methanol or ethanolcontaining less than about 2% water by volume.